Woodward easYgen-3000XT Series User manual

Option Manual
easYgen-3000XT Series
Genset Control
Release 2.11-0
Document ID: B37927, Revision A - Build 50798
easYgen-3000XT LITE
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Manual (original)
This is no translation but the original Technical Manual in English.
Designed in Germany.
Woodward GmbH
Handwerkstr. 29
70565 Stuttgart
Germany
Telephone: [phone]‑510
Fax: [phone]‑101
E-mail: [email protected]
Internet: http://www.woodward.com
© 2021 Woodward GmbH. All rights reserved.
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Brief Overview
NOTICE!
This option manual must be used together with the device standard manual. A option
manual only describes the additional functionality of the device. Please refer to “Reduced
functionality” for details.
Please use the suitable standard manual to install, commission and operate the device:
• easYgen-3100/3200XT-P1 manual (37574)•
The easYgen-3000XT series are control units for engine-generator system management
applications.
The control units can be used in applications such as: co-generation, stand-by, AMF, peak
shaving or distributed generation.
The easYgen-3000XT series is also applicable for islanded and mains parallel operations.
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Sample application setup
Fig. 1: Sample application setup
A typical application mode for the control unit is the use for mains parallel operation
application.
• In this case, the easYgens-XT will function as an engine control with generator,•
mains and engine protection.
• The control unit can open and close the generator circuit breaker (GCB) and the•
mains circuit breaker (MCB).
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For a listing of all available application modes please refer to the "Chapter: Application
Field" in easYgen-3000XT manual.
Reduced functionality
The easYgen-3000XT LITE controllers have some reduced functions compared to the
'standard' easYgen-3000XT controllers. The di󰍒erences are listed below.
• Busbar measurement•
Refer to
╚═▷ “2.1 Busbar measurement” for details.
• Import/Export control•
Refer to
╚═▷ “2.2 Import/Export control” for details.
• Load dependent start/stop (LDSS)•
Refer to
╚═▷ “2.3 Load dependent start/stop (LDSS)” for details.
•Load sharing •
Refer to
╚═▷ “2.4 Load sharing” for details.
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Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.1.1 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.2 Depiction Of Notes And Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7█
1.2.1 Copyright And Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8█
1.2.2 Service And Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9█
1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9█
1.3.1 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10█
1.3.2 General Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11█
1.3.3 Protective Equipment And Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14█
1.3.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14█
2 Reduced functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
2.1 Busbar measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15█
2.2 Import/Export control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16█
2.3 Load dependent start/stop (LDSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18█
2.4 Load sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19█
3Con󰍏guration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
3.1 Inputs And Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
3.1.1 Discrete Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21█
3.2 Con󰍓gure Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.2.1 Con󰍓gure Engine (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.3 Con󰍓gure Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.3.1 Con󰍓gure Breakers: GCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24█
3.3.2 Con󰍓gure Breakers: MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26█
4 Glossary And List Of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27█
5 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29█
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1 General Information
1.1 About This Manual
1.1.1 Revision History
Rev. Date Editor Changes in chronological descending order
A 2021-02 AS Option Manual - 1st issue
• Describing device software release 2.11-0•
1.2 Depiction Of Notes And Instructions
Safety instructions
Safety instructions are marked with symbols in these instructions. The safety instructions
are always introduced by signal words that express the extent of the danger.
DANGER!
This combination of symbol and signal word indicates an immediately-dangerous
situation that could cause death or severe injuries if not avoided.
WARNING!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indicates a possibly-dangerous situation that
could cause property and environmental damage if it is not avoided.
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Tips and recommendations
This symbol indicates useful tips and recommendations as well as information for
e󰍕cient and trouble-free operation.
Additional markings
To emphasize instructions, results, lists, references, and other elements, the following
markings are used in these instructions:
Marking Explanation
⚙Start of a procedure list
>Prerequisite for a procedure list
▷Step-by-step instructions
▶Results of action steps
╚═▷ References to sections of these instructions and to other relevant
documents
• Listing without 󰍓xed sequence
☼ Example
»Buttons« Operating elements (e.g. buttons, switches), display elements (e.g.
signal lamps)
»Display« Screen elements (e.g. buttons, programming of function keys)
[Screen xx / Screen xy / Screen
xz] ...
Menu path.
The following information and setting refer to a page on HMI screen or
ToolKit located as described here.
Some parameters/settings/screens are available only either in ToolKit or
in HMI/display.
Dimensions in Figures
All dimensions shown with no units speci󰍓ed are in mm.
1.2.1 Copyright And Disclaimer
Disclaimer
All information and instructions in this manual have been provided under due
consideration of applicable guidelines and regulations, the current and known state of the
art, as well as our many years of in-house experience. Woodward assumes no liability for
any damages due to:
• Failure to comply with the instructions in this manual•
• Improper use / misuse•
• Willful operation by non-authorized persons•
• Unauthorized conversions or non-approved technical modi󰍓cations•
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• Use of non-approved spare parts•
The originator is solely liable for the full extent for damages caused by such conduct. The
obligations agreed-upon in the delivery contract, the general terms and conditions, the
manufacturer’s delivery conditions, and the statutory regulations valid at the time the
contract was concluded, apply.
Copyright
This manual is protected by copyright. No part of this manual may be reproduced in any
form or incorporated into any information retrieval system without written permission of
Woodward GmbH.
Delivery of this manual to third parties, duplication in any form - including excerpts - as
well as exploitation and/or communication of the content, are not permitted without a
written declaration of release by Woodward GmbH.
Actions to the contrary will entitle us to claim compensation for damages. We expressly
reserve the right to raise any further accessory claims.
1.2.2 Service And Warranty
Our Customer Service is available for technical information.
For regional support, please refer to: ══▷ http://www.woodward.com/Support_pgd.aspx.
In addition, our employees are constantly interested in new information and experiences
that arise from usage and could be valuable for the improvement of our products.
Warranty terms
Please enquire about the terms of warranty from your nearest Woodward representative.
For our contact search webpage please go to: ══▷ http://www.woodward.com/
Directory.aspx
1.3 Safety
NOTICE!
Damage due to improper use!
Improper use of the device may cause damage to the device as well as connected
components.
Improper use includes, but is not limited to:
•Storage, transport, and operation outside the speci󰍓ed conditions. •
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1.3.1 Personnel
WARNING!
Hazards due to insu󰈢ciently quali󰈠ed personnel!
If unquali󰍓ed personnel perform work on or with the control unit hazards may arise which
can cause serious injury and substantial damage to property.
• Therefore, all work must only be carried out by appropriately quali󰍓ed personnel.•
This manual speci󰍓es the personnel quali󰍓cations required for the di󰍒erent areas of work,
listed below:
Personnel:
•Quali󰍏ed electrician•
The quali󰍓ed electrician is able to execute tasks on electrical equipment and
independently detect and avoid any possible dangers due to his training, expertise
and experience, as well as knowledge of all applicable regulations.
The quali󰍓ed electrician has been specially trained for the work environment in
which he is active and is familiar with all relevant standards and regulations.
•User •
The user operates the device within the limits of its intended use, without additional
previous knowledge but according to the instructions and safety notes in this
manual.
The workforce must only consist of persons who can be expected to carry out their work
reliably. Persons with impaired reactions due to, for example, the consumption of drugs,
alcohol, or medication are prohibited.
When selecting personnel, the age-related and occupation-related regulations governing
the usage location must be observed.
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1.3.2 General Safety Notes
Electrical hazards
DANGER!
Life-threatening hazard from electric shock!
There is an imminent life-threatening hazard from electric shocks from live parts.
Damage to insulation or to speci󰍓c components can pose a life-threatening hazard.
• Only a quali󰍓ed electrician should perform work on the electrical equipment.•
• Immediately switch o󰍒 the power supply and have it repaired if there is damage to•
the insulation.
• Before beginning work at live parts of electrical systems and resources, cut the•
electricity and ensure it remains o󰍒 for the duration of the work. Comply with the
󰍓ve safety rules in the process:
◦ cut electricity;◦
◦ safeguard against restart;◦
◦ ensure electricity is not 󰍔owing;◦
◦ earth and short-circuit; and◦
◦ cover or shield neighboring live parts.◦
• Never bypass a fuse or render it inoperable. Always use the correct amperage when•
changing a fuse.
• Keep moisture away from live parts. Moisture can cause short circuits.•
Prime mover safety
WARNING!
Hazards due to insu󰈢cient prime mover protection
The engine, turbine, or other type of prime mover should be equipped with an overspeed
(over-temperature, or over-pressure, where applicable) shutdown device(s), that
operates totally independently of the prime mover control device(s) to protect against
runaway or damage to the engine, turbine, or other type of prime mover with possible
personal injury or loss of life should the mechanical-hydraulic governor(s) or electric
control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.
Device implemented self test
this Woodward device has a self test check implemented. Permanently under control are:
•processor function and •
• supply voltage.•
The internal signal "self check" is aligned in series with the inverse signal »Ready for op.
OFF« parameter 12580. Per default (factory settings) discrete output R01 is energized/
closed if device itself is OK.
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LogicsManager (LM) equation parameter 12580 allows to customize this safety relay. You
can use the result of this equation: LM command variable 99.01 .
Be careful in changing safety relevant settings!
Modi󰈠cations
WARNING!
Hazards due to unauthorized modi󰈠cations
Any unauthorized modi󰍓cations to or use of this equipment outside its speci󰍓ed
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment.
Any unauthorized modi󰍓cations:
•constitute "misuse" and/or "negligence" within the meaning of the product warranty •
thereby excluding warranty coverage for any resulting damage
•invalidate product certi󰍓cations or listings. •
Use of batteries/alternators
NOTICE!
Damage to the control system due to improper handling
Disconnecting a battery from a control system that uses an alternator or battery-
charging device whilst the charging device is still connected causes damage to the
control system.
• Make sure the charging device is turned o󰍒 before disconnecting the battery from•
the system.
Unit includes a lithium backup battery for Real Time Clock. Field replacement of the
battery is not allowed.
In case of battery replacement please contact your Woodward service partner.
Electrostatic discharge
Before working with terminals please read the following instructions.
⚙
Preventing electrostatic discharge damage (ESD)
ᐳ
•Protective equipment: ESD wrist band
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NOTICE!
Damage from electrostatic discharge
• All electronic equipment sensitive to damage from electrostatic•
discharge, which can cause the control unit to malfunction or fail.
• To protect electronic components from static damage, take the•
precautions listed below.
1. ▷
Avoid build-up of static electricity on your body by not wearing clothing made of
synthetic materials. Wear cotton or cotton-blend materials as much as possible because
these do not store static electric charges as easily as synthetics.
2. ▷
Before working on terminals on the control unit, ground yourself by touching
and holding a grounded metal object (pipes, cabinets, equipment, etc.) to
discharge any static electricity.
Alternatively wear an ESD wrist band connected to ground.
3. ▷
Before any maintenance work on the control unit, ground yourself by
touching and holding a grounded metal object (pipes, cabinets, equipment,
etc.) to discharge any static electricity.
Alternatively wear an ESD wrist band connected to ground.
4. ▷
Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam cups,
cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, etc.)
away from the control unit, modules and work area.
5. ▷
Opening the control cover may void the unit warranty. Do not remove the printed circuit
board (PCB) from the control cabinet unless instructed by this manual.
If instructed by this manual to remove the PCB from the control cabinet,
follow these precautions:
• Ensure that the device is completely voltage-free (all connectors have•
to be disconnected).
• Do not touch any part of the PCB except the edges.•
• Do not touch the electrical conductors, connectors, or components with•
conductive devices or with bare hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic•
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
For additional information on how to prevent damage to electronic components caused
by improper handling, read and observe the precautions in:
• "Woodward manual 82715, Guide for Handling and Protection of Electronic Controls,•
Printed Circuit Boards, and Modules".
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1.3.3 Protective Equipment And Tools
Protective gear
Personal protective equipment serves to protect risks to the safety and health of persons
as well as to protect delicate components during work.
Certain tasks presented in this manual require the personnel to wear protective
equipment. Speci󰍓c required equipment is listed in each individual set of instructions.
The cumulative required personal protective equipment is detailed below:
Protective equipment: ESD wrist band
The ESD (electrostatic discharge) wrist band keeps the user's body set to ground
potential. This measure protects sensitive electronic components from damage due to
electrostatic discharge.
Tools
Use of the proper tools ensures successful and safe execution of tasks presented in this
manual.
Speci󰍓c required tools are listed in each individual set of instructions.
The cumulative required tools are detailed below:
1.3.4 Intended Use
The genset control unit has been designed and constructed solely for the intended use
described in this manual.
The easYgen-... devices are available in two di󰍒erent enclosures. They are designed to be
installed either on the back plate of a switch gear cabinet (e.g. easYgen-x100.../...-
x400...) or on the front plate of a switch gear panel (e.g. easYgen-x200.../...-x500...).The
terminals are always located on the inner side of the housing.
The genset control unit must be used exclusively for engine-generator system management
applications.
• Intended use requires operation of the control unit within the speci󰍓cations listed in the "Technical•
Data".
• All permissible applications are outlined in the "Application Modes".•
• Intended use also includes compliance with all instructions and safety notes presented in this manual.•
• Any use which exceeds or di󰍒ers from the intended use shall be considered improper use!•
• No claims of any kind for damage will be entertained if such claims result from improper use.•
14 easYgen-3000XT Series B37927
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1.3.3 Protective Equipment And Tools
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2 Reduced functionality
General notes
This chapter describes the reduced functionality only: this option device compared to the
standard device of the product series.
Please be aware that:
• some LogicsManager and AnalogManager variables•
• some Communication interface protocols contents•
• some Con󰍓guration settings•
are not available or not complete supported accordingly to the reduced functionality.
2.1 Busbar measurement
The busbar measurement is not available and the related measured values/parameter are
hidden.
Fig. 2: Toolkit HOME PAGE
The status and necessary references from the busbar (in range or dead) depends now
from the breaker feedback of the GCB and MCB
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• GCB and MCB are open•
◦ Busbar is dead◦
• GCB is closed and MCB is open•
◦ Busbar status is equal to the Generator status◦
◦ The synchronization (Synchronization MCB) uses the values from the Generator◦
and Mains.
• GCB is open and MCB is closed•
◦ Busbar status is equal to the Mains status◦
◦The synchronization (Synchronization GCB) uses the values from the Generator ◦
and Mains.
Phase angle for synchronization
The phase angle between Mains and Generator is used for the synchronization from the
GCB and MCB
Fig. 3: Toolkit Busbar/System/LSx
2.2 Import/Export control
The Import/Export control is not available in the device
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2.2 Import/Export control
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• Load control•
The control argument (selection) "Import/Export/Steady" for the four active power
setpoints is hidden. The active power controller is internaly 󰍓xed to "Steady".
Fig. 4: Toolkit Load setpoints
• PF/kvar control•
The enumeration for the two PF/kvar setpoint modes are still visible, but there is an
internal limitation from the control argument active.
◦PF setpoint ◦
Gen. PF → Gen. PF
Mains PF → Gen PF is internal used
◦ kvar setpoint◦
Gen. kvar → Gen. kvar
Mns. Export kvar → Gen kvar is internal used
Mns. Import kvar → Gen kvar is internal used
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2.2 Import/Export control
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Fig. 5: Toolkit PF/kvar setpoints
2.3 Load dependent start/stop (LDSS)
The load dependent start/stop functionality is internal disabled and not available.
All related con󰍓guration and sequencing pages are hidden and not visible.
18 easYgen-3000XT Series B37927
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2.3 Load dependent start/stop (LDSS)
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Fig. 6: Toolkit LDSS
2.4 Load sharing
The LITE version can operate only as a single device in isolated and parallel operation and
the load sharing with other devices is not available.
All related con󰍓guration and multi unit pages are hidden and not visible.
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Fig. 7: Toolkit Load share
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